2011 YAMAHA WR 450F steering

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART
(For Canada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
1 ClutchCheck operation.
√√√
Adjust or replace cable.
2 * Cooling systemCheck hoses for cracks of damage.
√√√
Replace if necessary.
Replace with ethylene glycol anti-freeze cool-
ant every 1 year.Every 1 year
3 * Spark arrester Clean.√
4 * Front brakeCheck operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brakeCheck operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hosesCheck for cracks or damage.√√
Replace. Every 4 years
7 * WheelsCheck runout, spoke tightness and for dam-
age.
√√√
Tighten spokes if necessary.
8*TiresCheck tread depth and for damage.
√√√ Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearingsCheck bearings for smooth operation.
√√√
Replace if necessary.
10 * Swingarm pivot bearingsCheck bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease.
11 Drive chainCheck chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearingsCheck bearing assemblies for looseness.
√√√ Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13Brake and clutch lever pivot
shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.√√√
14 Brake pedal pivot shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.√√√
3

3-6
MAINTENANCE INTERVALS FOR COMPETITION USE
FRONT FORKS
Inspect and adjust●●
Replace oil●●Suspension oil "S1"
Replace oil seal●
FRONT FORK OIL SEAL AND
DUST SEAL
Clean and lube●●Lithium base grease
PROTECTOR GUIDE
Replace●
REAR SHOCK ABSORBER
Inspect and adjust●●
Lube●(After
rain
ride)●Molybdenum disulfide grease
Retighten●●
DRIVE CHAIN GUIDE AND
ROLLERS
Inspect●●
SWINGARM
Inspect, lube and retighten●●Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD
Inspect, lube and retighten●●Molybdenum disulfide grease
SIDESTAND
Lubricate●Lithium base grease
STEERING HEAD
Inspect free play and retighten●●
Clean and lube●Lithium base grease
Replace bearing●
TIRE, WHEELS
Inspect air pressure, wheel run-
out, tire wear and spoke loose-
ness●●
Retighten sprocket bolt●●
Inspect bearings●
Replace bearings●
Lubricate●Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection●●
Lubricate●●Yamaha cable lube or SAE 10W-40
motor oil
HOT STARTER, CLUTCH LEVER
Inspect free play●
BATTERY
Check terminal for looseness
and corrosion● ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks

3-7
PRE-OPERATION INSPECTION AND MAINTENANCE
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation or practice, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator cap. Check the cool-
ing system for leakage.P.3-11 – 12
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the fuel
line for leakage.P.1-18
Engine oilCheck that the oil level is correct. Check the crankcase and oil
line for leakage.P.3-14 – 15
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-12
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-12 – 13
Brakes Check the play of front brake and effect of front and rear brake. P.3-19 – 22
Drive chainCheck drive chain slack and alignment. Check that the drive chain
is lubricated properly.P.3-22 – 23
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-26
SteeringCheck that the handlebar can be turned smoothly and have no ex-
cessive play.P.3-26 – 27
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage.
P.3-23 – 26
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.—
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.3-10 – 11
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-22
Lubrication Check for smooth operation. Lubricate if necessary. P.3-28
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-20
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-7
SettingsIs the machine set suitably for the condition of the course and
weather or by taking into account the results of test runs before
riding? Are inspection and maintenance completely done?P.4-1 – 10

3-26
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER HIGH COMPRESSION
DAMPING FORCE
1. Adjust:
• High compression damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of turns
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the adjuster body.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
CHECKING THE TIRE PRESSURE
1. Measure:
• Tire pressure
Out of specification→Adjust.
• Check the tire while it is cold.
• Loose bead stoppers allow the tire
to slip off its position on the rim
when the tire pressure is low.
• A tilted tire valve stem indicates that
the tire slips off its position on the
rim.
• If the tire valve stem is found tilted,
the tire is considered to be slipping
off its position. Correct the tire posi-
tion.
CHECKING AND TIGHTENING THE
SPOKES
The following procedure applies to all
of the spokes.
1. Check:
• Spokes
Bend/damage→Replace.
Loose spoke→Retighten.
Tap the spokes with a screw-
driver.
A tight spoke will emit a clear, ringing
tone; a loose spoke will sound flat.
2. Tighten:
• Spokes
(with a spoke nipple wrench "1")
Be sure to retighten these spokes be-
fore and after break-in.
CHECKING THE WHEELS
1. Inspect:
• Wheel runout
Elevate the wheel and turn it.
Abnormal runout→ Replace.
2. Inspect:
• Bearing free play
Exist play→Replace.
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Place a stand under the engine to
raise the front wheel off the
ground. WARNING! Securely
support the vehicle so that
there is no danger of it falling
over.
2. Check:
• Steering stem
Grasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play→Adjust steering head.
3. Check:
• Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action→Adjust steer-
ing ring nut. Stiffer "a" →Increase the high
compression damping force.
(Turn the adjuster "1" in.)
Softer "b" →Decrease the high
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position2 turns out
(from maximum
position)
Standard position:
About 1-1/8 turns out
* About 1-1/4 turns out
* For AUS, NZ and ZA
Standard tire pressure:
100 kPa (1.0 kgf/cm
2,
15 psi)
Spoke nipple wrench:
YM-01521/90980-01521
Spokes:
3 Nm (0.3 m•kg, 2.2
ft•lb)

3-27
CHASSIS
4. Adjust:
• Steering ring nut
Steering ring nut adjustment
steps:
a. Remove the headlight.
b. Remove the handlebar and upper
bracket.
c. Loosen the steering ring nut "1"
using the steering nut wrench "2".
d. Tighten the steering ring nut "3"
using steering nut wrench "4".
• Apply the lithium soap base grease
on the thread of the steering stem.
• Set the torque wrench to the steer-
ing nut wrench so that they form a
right angle.
e. Loosen the steering ring nut one
turn.
f. Retighten the steering ring nut us-
ing the steering nut wrench.
Avoid over-tightening.
g. Check the steering stem by turn-
ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
h. Install the washer "5", upper
bracket "6", washer "7", steering
stem nut "8", handlebar "9", han-
dlebar upper holder "10" and
headlight "11".
• The handlebar upper holder should
be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• Insert the end of the fuel breather
hose "12" into the hole in the steer-
ing stem.
First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
Steering nut wrench:
YU-33975/90890-01403
Steering nut wrench:
YU-33975/90890-01403
Steering ring nut (initial
tightening):
38 Nm (3.8 m•kg, 27
ft•lb)
Steering ring nut (final
tightening):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Steering stem nut:
145 Nm (14.5 m•kg, 105
ft•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20
ft•lb)
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Headlight:
7 Nm (0.7 m•kg, 5.1
ft•lb)

6-27
STEERING
STEERING
REMOVING THE STEERING
Order Part name Q'ty Remarks
A. For CDN
TIGHTENING STEPS:
• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)
• Loosen it one turn.
• Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb)
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Headlight
Handlebar Refer to "HANDLEBAR" section.
Front brake hose guide
Front fender
1 Multi-function display 1
2 Multi-function display bracket 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering stem nut 1
5 Front fork 2 Refer to "FRONT FORK" section.
6 Upper bracket 1
7 Steering ring nut 1 Refer to removal section.

6-28
STEERING
8 Lower bracket 1
9 Bearing race cover 1
10 Upper bearing 1
11 Lower bearing 1 Refer to removal section.
12 Bearing race 2 Refer to removal section. Order Part name Q'ty Remarks

6-29
STEERING
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE STEERING RING
NUT
1. Remove:
• Steering ring nut "1"
Use the steering nut wrench "2".
Support the steering stem so that
it may not fall down.
REMOVING THE LOWER
BEARING
1. Remove:
• Lower bearing "1"
Use the floor chisel "2".
Take care not to damage the steer-
ing shaft thread.
REMOVING THE BEARING RACE
1. Remove:
• Bearing race "1"
Remove the bearing race using
long rod "2" and the hammer.CHECKING THE STEERING STEM
1. Inspect:
• Steering stem "1"
Bend/damage→Replace.
CHECKING THE BEARING AND
BEARING RACE
1. Wash the bearings and bearing
races with a solvent.
2. Inspect:
•Bearing "1"
• Bearing race
Pitting/damage→Replace bear-
ings and bearing races as a set.
Install the bearing in the bearing
races. Spin the bearings by hand.
If the bearings hang up or are not
smooth in their operation in the
bearing races, replace bearings
and bearing races as a set.
INSTALLING THE LOWER
BRACKET
1. Install:
• Lower bearing "1"
Apply the lithium soap base grease
on the dust seal lip and bearing inner
circumference.
2. Install:
• Bearing race
• Upper bearing "1"
• Bearing race cover "2"
Apply the lithium soap base grease
on the bearing and bearing race cov-
er lip.
3. Install:
• Lower bracket "1"
Apply the lithium soap base grease
on the bearing, the portion "a" and
thread of the steering stem.
4. Install:
• Steering ring nut "1"
Tighten the steering ring nut using
the steering nut wrench "2".
Refer to "CHECKING AND AD-
JUSTING THE STEERING
HEAD" section in the CHAPTER
3.
5. Check the steering stem by turn-
ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings. Steering nut wrench:
YU-33975/90890-01403
Steering ring nut:
7 Nm (0.7 m•kg, 5.1
ft•lb)